2JZGTE E32 Conversion

[BMWTurbo]

Got the engine into the bay with some massaging and lube yesterday.

Few things that will need modifying, one brace for the inlet had to be removed, along with it's cast alloy lug for ABS unit clearance. Another bracket had to be relocated for the same reason. The cast dump section of the twin turbo's will probably need be removed, it isn't quiet hitting, but there isn't enough clearance to make me happy. I'll fabricate one from some steel to move it to a nicer location.

The oil filter fouled on the ABS unit also, this is the only thing I'll need a remedy for. I'll be sourcing a remote oil filter kit and using this to move the filter somewhere so it will not interfere.

Of note:- The engine is sitting slightly higher then where I'd ideally like it to the tune of approximately 35-40mm. As the car is only a DD I won't bother going to the extent of modifying the sump pan to get some of this back.

Photo attached is with the engine slightly on a lean to the right. This has been corrected and I have Engine mount jigs made for the correct location.

Engine mounts will be fabricated from thick walled RHS and 8-10mm plate. LHS and RHS will be different due to differing items in thier path.

Gearbox mount will be fabbed again from steel, with the Toyota mount being approximately 60mm offset centerline fowards compared to the BMW GB. New GB mount will be 6-9mm plate with some stiffeners along the lower face.

[BMWTurbo]

After making engine mount location Jig's wednesday night I raised the engine in the bay and set about making dummy mounts from thin walled steel first, to check clearances locations and cut angles etc, and will be cutting the finished mounts from 50x4 RHS tomorrow hopefully.

I will get some pictures this afternoon to show the complexity of the mounts. I'm pretty happy with the design now, but they took some out of the box thinking in order to get around obstacles, such as twin turbo actuators, steering boxs, turbo oil feed drains and radiator piping, and that is jsut one side

I also got together some more parts for the exhaust system. A new 12mm flange plate to make a custom collector/dump, a 3inch hi-flo CAT, barkley offset 3inch inlet and twin 2.5inch outlet muffler, and some flange plates etc.

The correct intercooler arrived yesterday also, 400x300x105 thick. It has KLS embossed onto the top and should be adequate for the job, though the cooler piping will be a fraction tight coming down in front of the radiator.

Tuesday I'll be getting the engine mounts welded up and will get them in and start on the gearbox crossmembet of which I have material for. This will then pave the way for tailshaft measurements.

Of note: - I managed to find an oil filter with a 3/4inch thread that is almost 20mm shorter then the toyota std one. By removing the inner ABS motor mount (leaving 2 others) I'll be able to fit this in with jsut enough clearance I think to be manageable. This will save on getting a remote oil filter kit.

[MadE21]

having evil thoughts about dads E32 now

[silverbullet]

how did u go bout the engine mount jigs? I am curious as to how u came up with the rite position and stuff. As many pics as possible would be appreciated!

[MadE21]

so what are you doing with the old 3.5?

[BMWTurbo]

Well bit of an interlude over christams and back to it.

Below are photo's of the jigs. These were takced in to place and bolted firmly into place so as to not move with the engine in the location I wanted it. I then lifted the engine up to allow access to the plates and bosses on the block to which the mounts would bolt to.

50x1.25ish RHS was used to create a template of the notches and lengths etc that would be required to fit and snake where needed. (these are the yellow ones). Once happy with the location and shape the parts were cut from 50x4 RHS ready to be takced together and once happy with thier location after some more trials, welded out.

The plates for the engine mount stud have been intentionally left off and are the last part to get welded after the rest of the mount is complete to allow any movement/play etc to be accounted for before finally locating the plates.

I'll be welding out the plates tonight, and have capped all open ends of the RHS for extra strength.

A few other things I've confirmed, I will require a 16inch thermo fan in place of the hydraulic fan Due to depth constraints. Had I mod'd the sump and allowed the engine to be another 15mm rearwards, I would have been able to retain the hydraulic fan. But this would have meant a 25mm odd scallop in the sump steel pan, which I'm not too keen on doing. I will however be 'massaging' to hopefully get around 8-10mm clearance between the sump and the crossmember.

Toyota ECU will not fit into the BMW factory ECU location in the bay and will have to be moved to inside the car. This sucks :P

BMW radiator will be retained, but I will probably fit an inline style filler and use an overflow bottle rather then the BMW system as the std bottle will not fit above the 2jz.

I've also attached a pic of some of the exhaust components compared to the std there should be a fair amount of weight saved. I have a box of mandrel bends to go along with this also and will leave provision for a resonator should the exhuast be too loud for my liking.

I'll be looking at the wiring soon as the weather has almost put a complete hault to workings on the engine/car.

As for the BM engine. I'll be inspecting the balancer and repairing anything strange there and then selling it It will be pretty much complete, right down to the coil, oil cooler,and even the airbox should I not use it.

[BMWTurbo]

Well managed to complete both engine mounts this afternoon and spend some time researching wiring and the wiring interface. I think I'll be cutting the BMW Large round plug (X20) and fitting another plug to interface with the Toyota Loom.

Engine is really starting to look at home I have my head around most things, with so far only one line to feed the powersteer/brake booster being need to be made aside from the the two A/C lines that will need to be reroute and possibly remade.

NExt on the agenda tomorro arfternoon will be the gearbox mount, which I've pretty much got a design in mind, then I'll start looking at the exhaust dump/collector just after the exhaust valve, down to where the CAT will be located.

[BMWTurbo]

Completed the Gearbox crossmember now. Fabricated from 6,8 and 10mm plate with a 30x3mm FB stiffener along the front edge. It came up fairly neat and I'm happy it will take the loads required easily.

Should be looking at the dump pipe tomorrow. Hopefully get that cracking so I can design the exhaust system.

I've set the tailshaft at the same level as the BMW and as the tailshaft is shorter and appears roughly the same size as the Toyota Yoke I think it should be a fairly straight foward shortening.

Of note:- The Aristo's rubber donut style coupling only JUST clears the shifter mechanism drop down by 5-10mm. The gearbox needs to be lowered in order to slip this over the nose on the gearbox so as not to foul.

[silverbullet]

Wow u work fast. Looking good!!!

[wayno]

Hey Ben im thinking of buyin an E28...you think i could get you to fab up some stuff for me? cause seriously we need to find you another hobby over the Christmas break?

But either way its looking good

[BMWTurbo]

Thanks Silver.. It's not going as fast as I'd like though due to other commitments. But christmas is a silly time really to do this :P

Wayno, I can lend a hand and offer some advice, I'm not very proficient at fabricating just yet, things take a while to make etc.

Today I purchased and fitted a 16inch thermo fan to the BMW radiator. Hopefully this will be enough flow as I was tossing up between twin 12inch and a single 16inch fan. I did leave off the BMW fan shroud though as the shroud shape extended past the radiator core, which as I was mounting the fan directly to the core I saw minimal gain in fitting. The fan can ONLY draw through the core though, so it should be okay.

I'll hopefully be able to get some access under the car tomorrow and start the exhaust dump etc. I'll also be looking at connecting the BMW cable style selector to the Toyota gearbox, which will involve a couple fo new brackets and a lever length change to get the full and correct engagement.

[sketchyturbo]

Stellar effort ben, you make a mockery of my projected timelines

[BMWTurbo]

Menaged to get the car down to the ramps on sunday late morning and get the dump pipe (Pipe that merges the twin outlets to a single 3inch) complete.

I'm fairly happy with it managing to get a minimum of 10mm clearance to the steering box heat shield and more then acceptable everwhere else. I'm running low on argosheild atm though so doubt I'll get to continue the exhaust any further tomorrow.

I will be sorting out the shifter and hopewfully get started on mounting the FMIC whilst I have reasonable access to the front of the car underside and topside.

I've also included a picture that shows the clearance to the BMW shift selctor plastic housing and another showing how much the BMW Tailshaft will need to be shortened and the yoke and donut it will need to mate up to.

[BMWTurbo]

Got some headway today. I managed to get the selector all but sorted, almost finish mounting the FMIC and finished the dump to CAT pipe ready for the rest of the system to be completed.

The first thing I tackled today was the gear selctor. I rigged up some measuring devices from wire and a nikko pen as a marker and measured the travel of the BMW gearbox selctor between P_R_N_D_3_2_1 and then did the same for the Toyota between P_R_N_D_2_1. Noticved one less shift movement. The bmw had a very narrow selector movement between each gear, around 7.2mm, wheres the toyota had 14.5mm approx between all but park which had up to 23mm.

After worknig out some more travels and ratio I decided I needed to shorten the Toyota selector arm from around 9mm centre to centre to 33.2mm centre to centre. I did this by cutting and shutting.

Next the BMW selector needed a bracket to be made to attach to the Toyota box, I fab'd this from some flatbar and held it in place under two of the sump pan bolts.

All that was left was to adapt the Toyota sector fork arm to the BMW cable style clamp, and I did this with some round bar, by drilling it out and fitting a locking screw to allow for adjustment if ever needed.

[BMWTurbo]

I then set about completing the pipe from the dump I made the other day to the CAT convertor. This wasn't too hard, but it came out under 45degrees which meant some playing with angles and cuts. All good experience though

I then started on the FMIC. Not happy about having to cut the bar, but it was the only way as the E32's from bar tucks back under the bumper rather then staying flush. I have the two top mounts in place. These came out nicely being able to be drilled into the front panel above the bar. As this metal was only thin I backed it with some 30x3 Angle to give it some strength. I'll be making some brackets up for the lower mounts tomorrow.

Hopefully will start on some piping tomorrow, and maybe make a start on the wiring. Tailshaft needs to be dropped off also.